Volume 05 - Surface Engineering Part 3 ppsx

μ μTable 1 Compositions and operating conditions of cyanide copper plating baths... Rochelle cyanide High-efficiency Constituent or conditionDilute cyanide strike Standard barrel Low con

Table 1 Parameters that characterize a state of residual stress in a finished component

Table 2 Fatigue life performance obtained by parts finished using various methods

Operation Endurance limit in bending

(10 7 cycles), MPa (ksi)

Relative endurance limit (a)

Table 3 Testing techniques for surface integrity evaluation

Surface integrity

factor considered

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Table 2 Single-point grinding temperatures

Temperature, °C, at wheel velocity of:

25 m/sec 32 m/sec 37 m/sec Material R

d

d

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Table 1 Selection guide for metalworking fluids for finishing operations

Work

materials

Thread gear, form

Centerless cylindrical

Internal Surface Abrasive

cutoff

Table 2 Maximum concentration of contaminants for the toxicity characteristic

EPA HW

No (a)

Contaminant CAS No (b) Regulatory

level, mg/L

Table 3 Trends in haulaway costs for spent coolant

Dollar cost per gallon

Region

Table 1 Relative grindability of work materials in wet outside diameter grinding

Relative grindability Work material Hardness

HRC

Water-soluble coolant

Oil coolant

Table 2 Physical and mechanical properties of selected ceramics, metals, and a polymer

temperature conductivity, k strength elasticity,

Ceramics

Metals

Polymer

Table 3 Matrix material that influences the finishing difficulty of typical composites Composite "Hard" matrix "Soft" matrix

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Table 1 Compositions and operating conditions of cyanide copper plating baths

Rochelle cyanide High-efficiency Constituent or condition

Dilute cyanide (strike)

Standard barrel

Low concentration (a)

High concentration (a)

Sodium cyanide (b)

Potassium cyanide (b)

Bath composition, g/L (oz/gal)

Bath analysis, g/L (oz/gal)

Operating conditions

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Table 2 Concentration limits and operating conditions of alkaline noncyanide copper plating baths

Table 3 Concentration limits and operating conditions of copper pyrophosphate plating baths Constituent or condition Strike Typical

Concentration limits, g/L (oz/gal)

Operating conditions

Table 4 Compositions and operating conditions of acid copper plating baths

Copper sulfate bath Copper fluoborate bath Constituent

or condition

General Printed circuit

through-hole

Low copper High copper

Bath composition, g/L (oz/gal)

Bath analysis, g/L (oz/gal)

Operating conditions

Copper plating in multiplate systems

Surface preparation

at current density, A/dm 2 (A/ft 2 )

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Table 7 Materials of construction for equipment basic to copper plating

Table 8 Materials for anodes and racks for use in copper plating

Plating bath Anodes

Table 1 Typical thicknesses and plating times for selected applications of hard chromium plating

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Chromic acid Sulfate Current density Bath temperature Type of oath

g/L oz/gal g/L oz/gal A/dm 2 A/in 2 °C °F

Table 3 Determination of chromic acid in chromium baths with a Baumé hydrometer

Chromic acid

°Bé

g/L oz/gal

Table 4 Conversion equivalents for chromic acid concentration in chromium baths

1140 (300)

1510 (400)

1890 (500)

2270 (600)

2650 (700)

3030 (800)

3410 (900)

3790 (1000)

Reagents

1140 (300)

1515 (400)

1890 (500)

2270 (600)

2650 (700)

3030 (800)

3410 (900)

3790 (1000)

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Table 6 Effect of bath temperature and current density on appearance and hardness of chromium deposits plated from a conventional sulfate solution

Plating bath at 43 °C (110 °F)

Plating bath at 49 °C (120 °F)

Plating bath at 54 °C (130 °F)

Table 7 Rates of deposition of hard chromium from low-concentration baths

Thickness of plate Plating time, h:min, at current

density, A/dm 2 (A/in 2 ), of:

(2.0)

47 (3.0)

62 (4.0)

Conventional sulfate bath (a)

Mixed catalyst bath (b)

39 A/dm 2 (2.5 A/in 2 )

47 A/dm 2 (3.0 A/in 2 )

54 A/dm 2 (3.5 A/in 2 )

Conventional sulfate bath (a)

Mixed catalyst bath (b)

Fluoride-free solution

Table 9 Process and equipment requirements for hard chromium plating using conventional solutions

Temperature

of bath

Tank dimensions Item

mm 2 in 2 mm 2 in 2

No

of pieces/

8 h

μm mil A/dm 2 A/in 2

Plating time, min

°C °F

No

of work rods

mm in.

Table 10 Design specifications for low-carbon steel tanks for hard chromium plating Size of tank

Thickness of low-carbon steel Width of rim

Tank reinforcing

Table 11 Lining materials for low-carbon steel tanks for hard chromium plating

Lining material Tank length

Lead alloy (a) PVC (b) Brick (c)

m ft kg/m 2 lb/ft 2 mm in mm in.

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Average relative abrasive hardness

Removal from steel or nickel-plated steel

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Table 1 Influence of design on platability of zinc-base die castings

Table 2 Compositions and operating conditions for two chromium plating baths Constituent or condition General decorative bath Bright, crack-free bath

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Table 3 Bath compositions and conditions for plating microcracked chromium

Constituents

Chromic acid Fluoride

Temperature Current density Substrate

material

g/L oz/gal g/L oz/gal

Chromic anhydride

to sulfate ratio

First plating bath

Second plating bath

Table 4 Typical system cycles

Total plate System Cycles

μm μin.

Total time, min (a)

Operating parameters

A: Copper strike

B: Acid copper plate, high speed, bright (20 μm, or 790 μin.)

C: Nickel plate, semibright (23 μm, or 900 μin.)

D: Nickel plate, bright (30 μm or 1180 μin.)

E: Nickel plate, bright (8 μm, or 315 μin.)

F: Chromium plate (0.3 μm, or μin.)

G: Chromium plate, microcracked (0.64 μm, or 25 μin.)

Table 5 Design basis of equipment for continuous chromium plating of zinc-base die castings

Designed current density

Table 6 Chromium plating maintenance schedule Frequency Action

Table 7 Chromium plating problems and corrections

Table 8 Case histories of plating problems Condition Cause and correction

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Table 9 Typical operating conditions for trivalent chromium processes

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Table 10 Trivalent and hexavalent chromium comparison

Nickel salts

Table 1 Nickel electrodeposition data

Time (min) required to obtain deposit at current density (A/dm 2 ) of: Deposit thickness, μm Weight

per unit area, g/dm 2

Amp hours per unit,

A · h/dm 2

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Table 2 Nickel electroplating solutions

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Table 3 Requirements for double- or triple-layer nickel coatings

Thickness as a percentage of total nickel thickness Type of nickel

coating (a)

Specific elongation,

%

Sulfur content, wt%

Double-layer Triple-layer

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Table 4 Coating systems on steel giving best performance after 15 years of outdoor marine exposure and 96

h of CASS testing

Type and thickness of coating, μm ASTM performance ratings

Copper Nickel (b) Chromium (c) Outdoor marine, 15 years CASS, 96 h

Table 5 Decorative nickel-plus-chromium coatings on steel

(typical applications)

Coating designation (a)

Minimum nickel thickness, μm

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Table 6 Other nickel plating solutions and some properties of the deposits

Type Composition (a) ,g/L pH Temperature,

°C

Cathode current density, A/dm 2

Vickers hardness,

100 g load

Tensile strength, MPa

Elongation,

%

Internal stress, MPa

Contaminant Maximum

concentration, ppm

Table 1 Typical iron plating solutions

°C

Current density

Component g/L Molarity

°C

A/m 2 A/ft 2

Table 2 Properties of electrodeposited iron coatings

Ultimate tensile strength Basic bath Additives

Elongation, % Hardness, HV

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Table 1(a) Compositions of cadmium plating cyanide solutions

Composition (a)

Cadmium oxide

Cadmium metal

Sodium cyanide

Sodium hydroxide (b)

Sodium carbonate (c)

Solution No Ratio of total

sodium cyanide

to cadmium metal

g/L oz/gal g/L oz/gal g/L oz/gal g/L oz/gal g/L oz/gal

Table 1(b) Operating conditions of cadmium plating cyanide solutions

Current density (a)

Range Average

Operating temperature

Table 2 Concentration of commercial noncyanide cadmium plating baths

Proprietary (a) Fluoborate (b) Bath

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Element Composition, %

Element(s) Composition

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Table 3 Time for plating cadmium to a given thickness at various current densities

Thickness of plate Plating time in minutes at current density specified

μm μin 54 A/m 2

(5 A/ft 2 )

110 A/m 2 (10 A/ft 2 )

160 A/m 2 (15 A/ft 2 )

215 A/m 2 (20 A/ft 2 )

270 A/m 2 (25 A/ft 2 )

325 A/m 2 (30 A/ft 2 )

Table 4 Recommended maintenance schedule for plating and auxiliary equipment

Daily

Monthly

Semiannually